Collapsed, tubular carton erecting apparatus

Abstract

An apparatus (10) for erecting collapsed, tubular cartons (12) is disclosed including a device (32) for removing the top carton (12) of a vertical stack of cartons (12) in a hopper (26) and moving it in a horizontal orientation to an operative position. In the operative position, the second side panel (16) of the collapsed carton (12) underlies at least the first end panel (18) which is in a linear arrangement with the first side panel (14). Suction cups (76) carried by a frame (74) are secured to the second side panel (16) in an attachment position and moved by a parallelogram linkage to an open position located vertically below and coinciding with the first side panel (14). In a first preferred form, the folded closure flaps (22-25) are held by a tape piece (116) applied by a taping machine (114) carried by the last tucking arm (106). In another preferred form, the folded closure flaps (22-25) are fan folded by rotating and sliding folding arms (140-143) of a device (120) so that tape pieces (116) or similar agents to hold the closure flaps (22-25) are not needed. An unload arm (84) is then pivoted about a first axis from a pickup position to a drop position and is simultaneously pivoted about a second axis from a first condition to a second condition to place the erected carton (12) in a chute (118) at an offset location and in a horizontal orientation. In the most preferred form, the unload arm (84) is pivoted about the second axis by a crank arm (98) secured to the unload arm (84) and a connector (100) having its opposite end secured to a stationary reference point when the unload arm (84) is pivoted about the first axis.

What is claimed is: 
     
       1. Device for erecting a collapsed carton, with the carton including first, second, third, and fourth side panels connected together about hinge connections, with the second and fourth panels being spaced and located intermediate the first and third side panels, with the carton including first and second major bottom closure flaps connected to the first and third side panels and first and second minor bottom closure flaps connected to the second and fourth side panels, comprising, in combination: a frame for supporting the third panel and including means for removable securement to the third panel; means for moving the frame from an attachment position and an open position, with the frame in the attachment position being vertically above and horizontally offset from the open position, with the frame being horizontally orientated in the attachment and open positions and intermediate the attachment and open positions; means for placing the carton at an operative position with the first and second panels in a linear arrangement and the third and fourth panels in a linear arrangement, with the third panel located vertically below and underlying at least the second panel and with the frame in the attachment position abutting the third panel, with the placing means holding the first panel at an operative position while the frame moves from the attachment position to the open position, with the closure flaps extending generally linearly to the first, second, third, and fourth panels in the operative position, with the closure flaps each including first and second outside corners; and means for pushing the first corner of the first major closure flap simultaneously inward and forward and prior to the second corner of the first minor closure flap, for pushing the first corner of the first minor closure flap simultaneously inward and forward and prior to the second corner of the second major closure flap, for pushing the first corner of the second major closure flap simultaneously inward and forward and prior to the second corner of the second minor closure flap, and for pushing the first corner of the second minor closure flap simultaneously inward and forward and prior to the second corner of the first major closure flap, with the first corners of the first and second major closure flaps and of the first and second minor flaps being pushed simultaneously until extending generally perpendicularly to the panels of the carton and forming the bottom of the carton. 
     
     
       2. The device of claim 1 further comprising, in combination: first means for holding the second corner of the first major flap when the closure flaps are initially pushed to insure that the first corner of the second minor closure flap is positioned forward of the second corner of the first major closure flap when the closure flaps extend generally perpendicular to the side panels; second means for holding the second corner of the first minor flap when the closure flaps are initially pushed to insure that the first corner of the first major closure flap is positioned forward of the second corner of the first minor closure flap when the closure flaps extend generally perpendicular to the side panels; third means for holding the second corner of the second major flap when the closure flaps are initially pushed to insure that the first corner of the first minor closure flap is positioned forward of the second corner of the second minor closure flap when the closure flaps extend generally perpendicular to the side panels; and fourth means for holding the second corner of the second minor flap when the closure flaps are initially pushed to insure that the first corner of the second minor closure flap is positioned forward of the second corner of the second major closure flap when the closure flaps extend generally perpendicular to the side panels. 
     
     
       3. The device of claim 2 wherein the placing means includes the first means for holding the second corner of the first major flap; and wherein the frame includes the third means for holding the second corner of the second major flap. 
     
     
       4. The device of claim 3 further comprising, in combination: an attachment arm movable between a pickup position and a drop position, with the attachment arm including means for attaching to the second panel and the second means for holding the second corner of the first minor closure flap. 
     
     
       5. The device of claim 4 wherein the fourth means for holding the second corner of the second minor flap is stationary. 
     
     
       6. Device for fan folding the first and second major closure flaps and the first and second minor closure flaps of the bottom of a tubular carton, with the closure flaps having hinged connections to side panels of the tubular carton and extending generally linearly to the side panels, with the closure flaps each including first and second outside corners, comprising, in combination: means for pushing the first corner of the first major closure flap simultaneously inward and forward and prior to the second corner of the first minor closure flap, for pushing the first corner of the first minor closure flap simultaneously inward and forward and prior to the second corner of the second major closure flap, for pushing the first corner of the second major closure flap simultaneously inward and forward and prior to the second corner of the second minor closure flap, and for pushing the first corner of the second minor closure flap simultaneously inward and forward and prior to the second corner of the first major closure flap, with the first corners of the first and second major closure flaps and of the first and second minor flaps being pushed simultaneously until extending generally perpendicularly to the side panels of the carton and forming the bottom of the carton. 
     
     
       7. The device of claim 6 further comprising, in combination: first means for holding the second corner of the first major flap when the closure flaps are initially pushed to insure that the first corner of the second minor closure flap is positioned forward of the second corner of the first major closure flap when the closure flaps extend generally perpendicular to the side panels; second means for holding the second corner of the first minor flap when the closure flaps are initially pushed to insure that the first corner of the first major closure flap is positioned forward of the second corner of the first minor closure flap when the closure flaps extend generally perpendicular to the side panels; third means for holding the second corner of the second major flap when the closure flaps are initially pushed to insure that the first corner of the first minor closure flap is positioned forward Of the second corner of the second minor closure flap when the closure flaps extend generally perpendicular to the side panels; and fourth means for holding the second corner of the second minor flap when the closure flaps are initially pushed to insure that the first corner of the second minor closure flap is positioned forward of the second corner of the second major closure flap when the closure flaps extend generally perpendicular to the side panels. 
     
     
       8. The device of claim 7 wherein the pushing means comprises, in combination: a first folding arm for pushing the first corner of the first major closure flap; a second folding arm for pushing the first corner of the first minor closure flap; a third folding arm for pushing the first corner of the second major closure flap; a fourth folding arm for pushing the first corner of the second minor closure flap; and means for moving the folding arms in a direction parallel to the side panels of the carton and perpendicular to the folding arms. 
     
     
       9. The device of claim 8 wherein the moving means comprises, in combination: a carriage; and means for slideably mounting the carriage for movement in the direction parallel to the side panels of the carton and perpendicular to the folding arms. 
     
     
       10. The device of claim 7 wherein the holding means each comprise a suction cup. 
     
     
       11. The device of claim 7 wherein the pushing means comprises, in combination: a first folding arm for pushing the first corner of the first major closure flap; a second folding arm for pushing the first corner of the first minor closure flap; a third folding arm for pushing the first corner of the second major closure flap; a fourth folding arm for pushing the first corner of the second minor closure flap; and means for simultaneously pivoting the first, second, third, and fourth folding arms about first, second, third, and fourth axes extending parallel to the side panels of the cartons and perpendicular to the folding arms. 
     
     
       12. The device of claim 11 wherein the pushing means further comprises, in combination: means for moving the folding arms in a direction parallel to the axes of the folding arms. 
     
     
       13. The device of claim 12 wherein the moving means comprises, in combination: a carriage, with the folding arms being pivotally mounted to the carriage; and means for slideably mounting the carriage for movement in the direction parallel to the axes of the folding arms between an inner position and an outer position. 
     
     
       14. The device of claim 13 wherein the simultaneously pivoting means comprises, in combination: first, second, third, and fourth crank arms movable with the first, second, third, and fourth folding arms, respectively, with the crank arms extending perpendicular to the axes of the folding arms; and linkage means for simultaneously pivoting the first, second, third, and fourth crank arms about the axes in the same direction. 
     
     
       15. The device of claim 14 wherein the linkage means comprises, in combination: first and second links secured together at an interconnection in an X-shape, with the first and second links being pivotally mounted to the carriage about an axis parallel to the axes of the folding arms and at the interconnection of the first and second links; first means pivotally connected to the first crank arm and an end of the first link; second means pivotally connected to the third crank arm and an opposite end of the first link; third means pivotally connected to the second crank arm and an end of the second link; and fourth means pivotally connected to the fourth crank arm and an opposite end of the second link; and means for pivoting the first and second links about the axis of the first and second links. 
     
     
       16. The device of claim 11 wherein the simultaneously pivoting means comprises, in combination: first, second, third, and fourth crank arms movable with the first, second, third, and fourth folding arms, respectively, with the crank arms extending perpendicular to the axes of the folding arms; and linkage means for simultaneously pivoting the first, second, third, and fourth crank arms about the axes in the same direction. 
     
     
       17. The device of claim 16 wherein the linkage means comprises, in combination: first and second links secured together at an interconnection in an x-shape, with the first and second links being pivotally mounted to the carriage about an axis parallel to the axes of the folding arms and at the interconnection of the first and second links; first means pivotally connected to the first crank arm and an end of the first link; second means pivotally connected to the third crank arm and an opposite end of the first link; third means pivotally connected to the second crank arm and an end of the second link; and fourth means pivotally connected to the fourth crank arm and an opposite end of the second link; and means for pivoting the first and second links about the axis of the first and second links. 
     
     
       18. The device of claim 6 wherein the pushing means comprises, in combination: a first folding arm for pushing the first corner of the first major closure flap; a second folding arm for pushing the first corner of the first minor closure flap; a third folding arm for pushing the first corner of the second major closure flap; a fourth folding arm for pushing the first corner of the second minor closure flap; means for simultaneously pivoting the first, second, third, and fourth folding arms about first, second, third, and fourth axes extending parallel to the side panels of the cartons and perpendicular to the folding arms; and means for moving the folding arms in a direction parallel to the axes of the folding arms as the folding arms are being simultaneously pivoted about the first, second, third, and fourth axes. 
     
     
       19. Method for fan folding the first and second major closure flaps and the first and second minor closure flaps of the bottom of a tubular carton, with the closure flaps having hinged connections to side panels of the tubular carton and extending generally linearly to the side panels, with the closure flaps each including first and second outside corners, comprising the steps of: pushing the first corner of the first major closure flap simultaneously inward and forward and prior to the second corner of the first minor closure flap; pushing the first corner of the first minor closure flap simultaneously inward and forward and prior to the second corner of the second major closure flap; pushing the first corner of the second major closure flap simultaneously inward and forward and prior to the second corner of the second minor closure flap; and pushing the first corner of the second minor closure flap simultaneously inward and forward and prior to the second corner of the first major closure flap, with the first corners of the first and second major closure flaps and of the first and second minor flaps being pushed simultaneously until extending generally perpendicularly to the side panels of the carton and forming the bottom of the carton. 
     
     
       20. The method of claim 19 further comprising the steps of: holding the second corner of the first major flap when the closure flaps are initially pushed to insure that the first corner of the second minor closure flap is positioned forward of the second corner of the first major closure flap when the closure flaps extend generally perpendicular to the side panels; holding the second corner of the first minor flap when the closure flaps are initially pushed to insure that the first corner of the first major closure flap is positioned forward of the second corner of the first minor closure flap when the closure flaps extend generally perpendicular to the side panels; holding the second corner of the second major flap when the closure flaps are initially pushed to insure that the first corner of the first minor closure flap is positioned forward of the second corner of the second minor closure flap when the closure flaps extend generally perpendicular to the side panels; and holding the second corner of the second minor flap when the closure flaps are initially pushed to insure that the first corner of the second minor closure flap is positioned forward of the second corner of the second major closure flap when the closure flaps extend generally perpendicular to the side panels.